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JP2007283286A - Method for manufacturing plugged honeycomb structure - Google Patents

Method for manufacturing plugged honeycomb structure Download PDF

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JP2007283286A
JP2007283286A JP2007015514A JP2007015514A JP2007283286A JP 2007283286 A JP2007283286 A JP 2007283286A JP 2007015514 A JP2007015514 A JP 2007015514A JP 2007015514 A JP2007015514 A JP 2007015514A JP 2007283286 A JP2007283286 A JP 2007283286A
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Prior art keywords
honeycomb structure
face
light
plugged
thermosetting resin
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Yukihito Ichikawa
結輝人 市川
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NGK Insulators Ltd
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NGK Insulators Ltd
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Priority to JP2007015514A priority Critical patent/JP2007283286A/en
Priority to US11/714,731 priority patent/US20070221312A1/en
Publication of JP2007283286A publication Critical patent/JP2007283286A/en
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    • CCHEMISTRY; METALLURGY
    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B38/00Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof
    • C04B38/0006Honeycomb structures
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B01PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01DSEPARATION
    • B01D46/00Filters or filtering processes specially modified for separating dispersed particles from gases or vapours
    • B01D46/0001Making filtering elements
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B01PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01DSEPARATION
    • B01D46/00Filters or filtering processes specially modified for separating dispersed particles from gases or vapours
    • B01D46/24Particle separators, e.g. dust precipitators, using rigid hollow filter bodies
    • B01D46/2403Particle separators, e.g. dust precipitators, using rigid hollow filter bodies characterised by the physical shape or structure of the filtering element
    • B01D46/2418Honeycomb filters
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B01PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01JCHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J35/00Catalysts, in general, characterised by their form or physical properties
    • B01J35/50Catalysts, in general, characterised by their form or physical properties characterised by their shape or configuration
    • B01J35/56Foraminous structures having flow-through passages or channels, e.g. grids or three-dimensional monoliths
    • B01J35/57Honeycombs
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B28WORKING CEMENT, CLAY, OR STONE
    • B28BSHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B11/00Apparatus or processes for treating or working the shaped or preshaped articles
    • B28B11/003Apparatus or processes for treating or working the shaped or preshaped articles the shaping of preshaped articles, e.g. by bending
    • B28B11/006Making hollow articles or partly closed articles
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B28WORKING CEMENT, CLAY, OR STONE
    • B28BSHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B11/00Apparatus or processes for treating or working the shaped or preshaped articles
    • B28B11/003Apparatus or processes for treating or working the shaped or preshaped articles the shaping of preshaped articles, e.g. by bending
    • B28B11/006Making hollow articles or partly closed articles
    • B28B11/007Using a mask for plugging
    • CCHEMISTRY; METALLURGY
    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B35/00Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/01Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics
    • C04B35/16Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on silicates other than clay
    • C04B35/18Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on silicates other than clay rich in aluminium oxide
    • C04B35/195Alkaline earth aluminosilicates, e.g. cordierite or anorthite
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B01PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01DSEPARATION
    • B01D2279/00Filters adapted for separating dispersed particles from gases or vapours specially modified for specific uses
    • B01D2279/30Filters adapted for separating dispersed particles from gases or vapours specially modified for specific uses for treatment of exhaust gases from IC Engines
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B01PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01JCHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J23/00Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00
    • B01J23/38Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of noble metals
    • B01J23/40Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of noble metals of the platinum group metals
    • CCHEMISTRY; METALLURGY
    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/00034Physico-chemical characteristics of the mixtures
    • C04B2111/00129Extrudable mixtures
    • CCHEMISTRY; METALLURGY
    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/00474Uses not provided for elsewhere in C04B2111/00
    • C04B2111/00793Uses not provided for elsewhere in C04B2111/00 as filters or diaphragms
    • CCHEMISTRY; METALLURGY
    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/00474Uses not provided for elsewhere in C04B2111/00
    • C04B2111/0081Uses not provided for elsewhere in C04B2111/00 as catalysts or catalyst carriers

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Ceramic Engineering (AREA)
  • Structural Engineering (AREA)
  • Organic Chemistry (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Materials Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Geometry (AREA)
  • Manufacturing & Machinery (AREA)
  • Filtering Materials (AREA)
  • Devices For Post-Treatments, Processing, Supply, Discharge, And Other Processes (AREA)

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method for producing a sealed honeycomb structure, which makes it possible to provide a uniform sealing depth for a honeycomb structure and produce such a sealed honeycomb structure conveniently at low cost. <P>SOLUTION: All cells 42 of a honeycomb structure 41 are filled with a slurry sealing agent 43. Separately, an image of the end face cells of the honeycomb structure 41 is taken with a camera 40. A light-cured or thermosetting resin film 44 is applied onto the end face of the honeycomb structure 41 with all cells sealed and then a sealing pattern is printed on the film 44. After printing, the honeycomb structure 41 to which the film 44a is applied is exposed to light or heat using a light source or heat source 50. Thus, only target membrane portions 45 are cured. Uncured membrane portions 48 and uncured cell portions 47 are removed together with a sealing material 49 by the use of pressurized air and a sandblast Y. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

本発明は、目封止ハニカム構造体の製造方法に関する。さらには、フィルタ等に用いた場合に、その端面への堆積物の堆積が低減された目封止ハニカム構造体を、簡便かつ低コストに製造することが可能な目封止ハニカム構造体の製造方法に関する。さらに詳しくは、ハニカム構造体の目封止深さを簡便に均一化することが可能な目封止ハニカム構造体の製造方法に関する。   The present invention relates to a method for manufacturing a plugged honeycomb structure. Furthermore, when used in a filter or the like, the production of a plugged honeycomb structure capable of producing a plugged honeycomb structure with reduced deposit accumulation on its end face easily and at low cost Regarding the method. More specifically, the present invention relates to a method for manufacturing a plugged honeycomb structure capable of easily uniformizing the plugging depth of the honeycomb structure.

近年、化学、電力、鉄鋼、産業廃棄物処理をはじめとする様々な分野において、公害防止等の環境対策、高温ガスからの製品回収等の用途で用いられる集塵用のフィルタとして、耐熱性、耐食性に優れるセラミックからなる目封止ハニカム構造体が用いられている。例えば、このような目封止ハニカム構造体は、ディーゼル機関から排出されるパティキュレートを捕集するディーゼルパティキュレートフィルタ(DPF)等の高温、腐食性ガス雰囲気下において使用される集塵用フィルタとして好適に用いられている(例えば、特許文献1)。   In recent years, in various fields including chemical, electric power, steel, and industrial waste treatment, as a filter for dust collection used for environmental measures such as pollution prevention, product recovery from high temperature gas, etc., heat resistance, A plugged honeycomb structure made of ceramic having excellent corrosion resistance is used. For example, such a plugged honeycomb structure is used as a dust collection filter used in a high temperature, corrosive gas atmosphere such as a diesel particulate filter (DPF) that collects particulates discharged from a diesel engine. It is used suitably (for example, patent document 1).

上記のような集塵用フィルタとして用いられる目封止ハニカム構造体は、図7に示すように、流体の流路となる複数のセル24を区画形成する多孔質の隔壁22を有する筒状のハニカム構造体23と、所定のセルの一方の開口部を目封止するとともに残余のセルの他方の開口部を目封止する目封止部材26とを備えたものである。図7に示す目封止ハニカム構造体21においては、目封止部材26が、複数のセル24の入口側端面Bと出口側端面Cとを互い違いに目封止している。   As shown in FIG. 7, the plugged honeycomb structure used as a dust collecting filter as described above has a cylindrical shape having porous partition walls 22 that define a plurality of cells 24 that serve as fluid flow paths. A honeycomb structure 23 and a plugging member 26 that plugs one opening of a predetermined cell and plugs the other opening of the remaining cells are provided. In the plugged honeycomb structure 21 shown in FIG. 7, the plugging members 26 plug the inlet side end surfaces B and the outlet side end surfaces C of the plurality of cells 24 alternately.

上記のような目封止ハニカム構造体21は、押出し成形によって、流体の流路となる複数のセルを区画形成する多孔質の隔壁を有する筒状の未焼成ハニカム構造体を得た後、得られた未焼成ハニカム構造体又はこの未焼成ハニカム構造体を焼成したハニカム構造体の所定のセルの一方の開口部と、残余のセルの他方の開口部とに、セラミックを含む目封止スラリーを充填した後に焼成することによって製造することができる。   The plugged honeycomb structure 21 as described above is obtained by obtaining a cylindrical unfired honeycomb structure having porous partition walls that define a plurality of cells serving as fluid flow paths by extrusion molding. A plugging slurry containing ceramic is formed in one opening of a predetermined cell of the obtained unfired honeycomb structure or the honeycomb structure obtained by firing the unfired honeycomb structure and the other opening of the remaining cells. It can manufacture by baking after filling.

さらに、上記のような集塵用フィルタとして用いられる目封止ハニカム構造体の従来の製造方法を図6(a)(b)に示す。図6(a)のように、例えば、未焼成のセラミック乾燥体であるハニカム成形体1の一方の端面に、フィルム2を貼着し、画像処理を利用したレーザー加工等によりそのフィルム2の目封止すべきセル(目封止セル)に対応する部分3にのみ孔開けをしてマスク4とし、次いで、図6(b)のように、マスク4が貼着されたハニカム成形体1の端面をスラリー(セラミックスラリー)5中に浸漬し、ハニカム成形体1の目封止セルにスラリー5を充填して目封止部を形成し、これと同様の工程をハニカム成形体1の他方の端面についても行った後、乾燥し、焼成することにより目封止ハニカム構造体を得る方法が提案されている(例えば、特許文献2)。   Furthermore, the conventional manufacturing method of the plugged honeycomb structure used as a filter for dust collection as described above is shown in FIGS. As shown in FIG. 6A, for example, the film 2 is adhered to one end face of the honeycomb formed body 1 which is an unfired ceramic dried body, and the eyes of the film 2 are obtained by laser processing using image processing or the like. The honeycomb molded body 1 to which the mask 4 is adhered as shown in FIG. 6B is formed by making holes only in the portions 3 corresponding to the cells to be sealed (plugged cells). The end face is immersed in a slurry (ceramic slurry) 5 and the plugging cells of the honeycomb formed body 1 are filled with the slurry 5 to form plugged portions. The same process is performed on the other side of the honeycomb formed body 1. There has been proposed a method of obtaining a plugged honeycomb structure by performing drying on the end face, followed by firing and firing (for example, Patent Document 2).

特開2001−300922号公報Japanese Patent Laid-Open No. 2001-300922 特開2005−270755号公報JP 2005-270755 A

上記のような目封止ハニカム構造体の製造方法は、フィルムにレーザー穴開けする方法では穴がセル開口よりも小さめとなり易いので、目封止材をセル内へ充填する際に目封止材がセル内へ入り難い場合がある。またハニカム構造体の外周部における不完全セルにおいては、穴径を小さくする必要があり、レーザー照射条件の変更が必要となり、穴開けが複雑化するという問題があった。   In the method of manufacturing the plugged honeycomb structure as described above, the hole is likely to be smaller than the cell opening in the method of laser drilling in the film, so the plugging material is used when filling the plugging material into the cell. May not be able to enter the cell. In addition, in the incomplete cells in the outer peripheral portion of the honeycomb structure, it is necessary to reduce the hole diameter, and it is necessary to change the laser irradiation conditions, and there is a problem that the drilling is complicated.

本発明者は、セル形状のセル開口と概ね同一の穴とすることにより、目封止材をセル内へ充填する際に目封止材がセル内へ入り難いという課題と、穴開けの簡便化をはかるという課題を解決した製造方法を提供することを目的として、本発明に到達した。   The present inventor has a problem that the plugging material is difficult to enter into the cell when filling the plugging material into the cell by making the hole substantially the same as the cell-shaped cell opening, and easy opening of the hole. The present invention has been achieved with the object of providing a manufacturing method that solves the problem of achieving the above.

上記課題を達成するため、本発明は、以下の目封止ハニカム構造体の製造方法を提供するものである。   In order to achieve the above object, the present invention provides the following method for manufacturing a plugged honeycomb structure.

[1]多孔質の隔壁によって流体の流路となる複数のセルがハニカム状に区画形成された筒状ハニカム構造体の所定のセルの一方の開口端部に目封止部が形成された目封止ハニカム構造体の製造方法において、予めハニカム構造体の端面を撮像し、次いで、予め決められた目封止パターンを撮像されたハニカム構造体端面の端面セル群に画像処理により合成し、得られた合成画像をハニカム構造体端面に形成された光又は熱硬化樹脂膜に印刷した後、ハニカム構造体端面に光又は熱を照射し、硬化した個所を残して除去することにより、前記光又は熱硬化樹脂膜に所定の目封止パターンを有する開口部を形成し、ハニカム構
造体のセル内へ目封止材を充填して目封止部を形成することを特徴とする目封止ハニカム構造体の製造方法。
[1] A plug in which a plugged portion is formed at one open end of a predetermined cell of a tubular honeycomb structure in which a plurality of cells serving as fluid flow paths are formed in a honeycomb shape by porous partition walls In the manufacturing method of the sealed honeycomb structure, the end face of the honeycomb structure is imaged in advance, and then a predetermined plugging pattern is synthesized by image processing on the end face cell group of the captured honeycomb structure end face. After the printed composite image is printed on the light or thermosetting resin film formed on the end surface of the honeycomb structure, the light or heat is irradiated to the end surface of the honeycomb structure, and the cured portion is removed to remove the light or the heat. A plugged honeycomb, wherein an opening having a predetermined plugging pattern is formed in a thermosetting resin film, and a plugging material is filled into cells of the honeycomb structure to form a plugged portion. Manufacturing method of structure.

[2]予め光又は熱硬化樹脂フィルムに合成した目封止パターンを印刷しておき、そのフィルムをハニカム構造体端面に貼り付ける前記[1]記載の目封止ハニカム構造体の製造方法。 [2] The method for manufacturing a plugged honeycomb structure according to [1], wherein a plugged pattern synthesized in advance on a light or thermosetting resin film is printed, and the film is attached to an end face of the honeycomb structure.

[3]多孔質の隔壁によって流体の流路となる複数のセルがハニカム状に区画形成された筒状ハニカム構造体の所定のセルの一方の開口端部に目封止部が形成された目封止ハニカム構造体の製造方法において、予めハニカム構造体端面の全セルに目封止材を充填した後、その端面に光又は熱硬化樹脂膜を形成して、予めハニカム構造体の端面を撮像し、次いで、予め決められた目封止パターンを撮像されたハニカム構造体端面の端面セル群に画像処理により合成し、得られた合成画像をハニカム構造体端面に形成された光又は熱硬化樹脂膜に印刷した後、ハニカム構造体端面に光又は熱を照射して所定のセルの光又は熱硬化樹脂膜を硬化させ、硬化しなかった光又は熱硬化樹脂膜を目封止材とともに除去した後、硬化した光又は熱硬化樹脂膜を除去することにより目封止部を形成することを特徴とする目封止ハニカム構造体の製造方法。 [3] A plug having a plugged portion formed at one open end of a predetermined cell of a tubular honeycomb structure in which a plurality of cells serving as fluid flow paths are formed in a honeycomb shape by porous partition walls In the manufacturing method of the sealed honeycomb structure, after all the cells on the end face of the honeycomb structure are filled with a plugging material in advance, a light or thermosetting resin film is formed on the end face, and the end face of the honeycomb structure is previously imaged. Then, a predetermined plugging pattern is synthesized by image processing on the end face cell group of the end face of the honeycomb structure imaged, and the obtained composite image is light or thermosetting resin formed on the end face of the honeycomb structure body After printing on the membrane, the end surface of the honeycomb structure is irradiated with light or heat to cure the light or thermosetting resin film of a predetermined cell, and the uncured light or thermosetting resin film is removed together with the plugging material. After cured light or thermoset resin film Method for manufacturing a plugged honeycomb structure and forming plugging portions by removing.

[4]多孔質の隔壁によって流体の流路となる複数のセルがハニカム状に区画形成された筒状ハニカム構造体の所定のセルの一方の開口端部に目封止部が形成された目封止ハニカム構造体の製造方法において、予め目封止材に光又は熱硬化樹脂を含有しておき、その目封止材をハニカム構造体の全セルに充填し、予め撮像されたハニカム構造体の端面画像情報に基づいて、端面を目封止パターン状にレーザー照射することで、所定のセルの目封止材を硬化させ、硬化しなかった目封止材を除去することにより目封止部を形成することを特徴とする目封止ハニカム構造体の製造方法。 [4] A plug having a plugged portion formed at one open end of a predetermined cell of a tubular honeycomb structure in which a plurality of cells serving as fluid flow paths are formed in a honeycomb shape by porous partition walls In a method for manufacturing a sealed honeycomb structure, a honeycomb structure in which light or thermosetting resin is previously contained in the plugging material, the cells are filled in all the cells of the honeycomb structure, and the honeycomb structure is imaged in advance. Based on the end face image information, the end face is irradiated with a laser in a plugging pattern so that the plugging material of a predetermined cell is cured and the plugging material that has not been cured is removed. A method for manufacturing a plugged honeycomb structure, wherein a portion is formed.

[5]多孔質の隔壁によって流体の流路となる複数のセルがハニカム状に区画形成された
筒状ハニカム構造体の所定のセルの一方の開口端部に目封止部が形成された目封止ハニカム構造体の製造方法において、予めハニカム構造体端面の全セルに目封止材を充填した後、その端面に光又は熱硬化樹脂膜を形成し、次いで、予め撮像されたハニカム構造体の端面画像情報に基づいて、端面を目封止パターン状にレーザー照射することで、所定のセルの光又は熱硬化樹脂膜を硬化させ、硬化しなかった光又は熱硬化樹脂膜を目封止材とともに除去した後、硬化した光又は熱硬化樹脂膜を除去することにより目封止部を形成することを特徴とする目封止ハニカム構造体の製造方法。
[5] A plug having a plugged portion formed at one open end of a predetermined cell of a tubular honeycomb structure in which a plurality of cells serving as fluid flow paths are formed in a honeycomb shape by porous partition walls In the method for manufacturing a sealed honeycomb structure, after all the cells on the end face of the honeycomb structure are filled with a plugging material in advance, a light or thermosetting resin film is formed on the end face, and then the honeycomb structure is imaged in advance. By irradiating the end face with a laser in a plugging pattern based on the end face image information, the light or thermosetting resin film of a predetermined cell is cured and the uncured light or thermosetting resin film is plugged. A method for manufacturing a plugged honeycomb structure, wherein the plugged portion is formed by removing the cured light or thermosetting resin film after removing together with the material.

本発明の製造方法によると、以下の効果を有する。すなわち、撮像された端面のセル形状に基づき、フィルムに印刷された目封止パターンに沿って、フィルムに穴が開けられるので、穴はセル開口と概ね同一とすることが出来る。そのため、目封止材がセル内へ入り易くなり、目封止材をセル内へ充填する際に目封止材がセル内へ入り難いという課題が解決される。また、ハニカム構造体の最外周の不完全セルでも同様にセル開口と概ね同一の穴加工が可能となるので、穴開けの簡便化をはかるという課題も解決される。更に、予めハニカム構造体端面の全セルに目封止材を充填したのちその端面に光又は熱硬化樹脂膜を形成する、あるいは、光又は熱硬化樹脂を含有した目封止材を充填し目封止するセルの部分のみ樹脂を硬化する本発明の別の実施態様では、目封止材をセル内へ充填する際に目封止材がセル内へ入り難いという課題の解決のみならず、硬化されなかった樹脂は容易に除去できるので、穴開けの簡便化をはかるという課題も解決される。   The production method of the present invention has the following effects. That is, since a hole is made in the film along the plugging pattern printed on the film based on the cell shape of the imaged end face, the hole can be made substantially the same as the cell opening. Therefore, the problem that the plugging material easily enters the cell and the plugging material hardly enters the cell when the plugging material is filled into the cell is solved. In addition, the incomplete cells on the outermost periphery of the honeycomb structure can be processed with holes substantially the same as the cell openings, so that the problem of simplifying the drilling is also solved. Further, after filling the plugging material in all cells on the end face of the honeycomb structure in advance, a light or thermosetting resin film is formed on the end face, or a plugging material containing light or thermosetting resin is filled. In another embodiment of the present invention in which only the portion of the cell to be sealed is cured, not only is the solution of the problem that the plugging material hardly enters the cell when filling the plugging material into the cell, Since the uncured resin can be easily removed, the problem of simplifying drilling is also solved.

以下、図1から図5の本発明の具体的形態を参照して、本発明の目封止ハニカム構造体の製造方法の実施の形態について詳細に説明するが、本発明は、これに限定されて解釈されるものではなく、本発明の範囲を逸脱しない限りにおいて、当業者の知識に基づいて、種々の変更、修正、改良を加え得るものである。   Hereinafter, embodiments of the method for manufacturing a plugged honeycomb structure of the present invention will be described in detail with reference to the specific embodiments of the present invention shown in FIGS. 1 to 5, but the present invention is not limited thereto. However, various changes, modifications, and improvements can be made based on the knowledge of those skilled in the art without departing from the scope of the present invention.

本発明に用いる目封止部材は、セラミックの粉末、例えば、コージェライトの粉末に、バインダーや分散媒等を加えて混練したものを目封止材として好適に用いることができる。例えば、コージェライト粉末に水、バインダー、グリセリンを入れて目封止部材を調製することができる。   As the plugging member used in the present invention, a ceramic powder, for example, a cordierite powder added with a binder or a dispersion medium and kneaded can be suitably used as a plugging material. For example, a plugging member can be prepared by adding water, a binder, and glycerin to cordierite powder.

また、本発明のハニカム構造体の材質については、強度、耐熱性等の観点から、コージェライト、炭化珪素、アルミナ、ムライト、アルミニウムチタネイト及びLAS(リチウムアルミニウムシリケート)からなる群より選ばれたいずれか1種を主結晶相とすることが好ましい。なお、目封止材のスラリーを、ハニカム構造体と同一にすると、両者の熱膨張率が一致するという効果がある。   The material of the honeycomb structure of the present invention is selected from the group consisting of cordierite, silicon carbide, alumina, mullite, aluminum titanate, and LAS (lithium aluminum silicate) from the viewpoint of strength, heat resistance, and the like. It is preferable to use one of these as the main crystal phase. If the plugging material slurry is the same as that of the honeycomb structure, the thermal expansion coefficients of the two are the same.

多孔質の隔壁によって流体の流路となる複数のセルがハニカム状に区画形成された筒状ハニカム構造体は、例えば、特許文献2記載の方法で製造される。例えば、セラミックを含む成形原料を押出し成形して、流体の流路となる複数のセルを区画形成する多孔質の隔壁を有する筒状の未焼成ハニカム構造体を得ることができる。セラミックを含む成形原料は、コージェライト、ムライト、アルミナ、スピネル、炭化珪素、窒化珪素、リチウムアルミニウムシリケート、チタン酸アルミニウム等のセラミックの粉末に、バインダーや分散媒等を加えて混練したものを好適に用いることができる。押出し成形の方法として特に制限はないが、例えば、真空押出し成形機を用いた押出し成形等の従来公知の方法を用いることができる。   A tubular honeycomb structure in which a plurality of cells serving as fluid flow paths are formed in a honeycomb shape by porous partition walls is manufactured, for example, by the method described in Patent Document 2. For example, a cylindrical unfired honeycomb structure having porous partition walls that form a plurality of cells serving as fluid flow paths can be obtained by extruding a forming raw material containing ceramic. The molding raw material containing ceramic is preferably a ceramic powder such as cordierite, mullite, alumina, spinel, silicon carbide, silicon nitride, lithium aluminum silicate, aluminum titanate, etc., kneaded with a binder or dispersion medium added. Can be used. Although there is no restriction | limiting in particular as a method of extrusion molding, For example, conventionally well-known methods, such as extrusion molding using a vacuum extrusion molding machine, can be used.

図1(a)〜(e)は、本発明における、ハニカム構造体端面のフィルムへの印刷工程を説明したものである。この実施形態では、図1(a)に示すように、まず、ハニカム構造体11の端面のセル画像をカメラ18により撮像して、図1(b)のようなセル画像14を得る。次いで、予め決められた目封止パターンを、得られたセル画像14と画像処理により合成して、図1(c)のような合成画像15を得る。一方、図1(d)に示すように、ハニカム構造体11の端面に光又は熱硬化樹脂膜(フィルム)16を貼り付けておき、図1(e)のように、上記で得られた合成画像15をこの光又は熱硬化樹脂膜(フィル
ム)16に印刷し、印刷済みフィルム17を得る。
Fig.1 (a)-(e) demonstrates the printing process to the film of the honeycomb structure end surface in this invention. In this embodiment, as shown in FIG. 1A, first, a cell image of the end face of the honeycomb structure 11 is captured by the camera 18 to obtain a cell image 14 as shown in FIG. Next, a predetermined plugging pattern is synthesized with the obtained cell image 14 by image processing to obtain a synthesized image 15 as shown in FIG. On the other hand, as shown in FIG. 1 (d), a light or thermosetting resin film (film) 16 is pasted on the end face of the honeycomb structure 11, and the synthesis obtained above as shown in FIG. 1 (e). The image 15 is printed on the light or thermosetting resin film (film) 16 to obtain a printed film 17.

本発明で、光硬化樹脂とは、紫外光、可視光によって硬化する樹脂をいう。例えば、パルスレーザー光、He−Cdレーザー光、アルゴンレーザー光によって樹脂の光の当たった部分が重合して硬化するものであり、エポキシ系のものが汎用性があり、好ましい。   In the present invention, the photocurable resin means a resin that is cured by ultraviolet light or visible light. For example, the resin-lighted portion is polymerized and cured by pulsed laser light, He—Cd laser light, or argon laser light, and an epoxy-based material is preferred because of its versatility.

また、熱硬化樹脂とは、加熱等により分子間に架橋反応が起こって三次元網目構造の不溶の高分子に変化する性質を有する液性又は粉状の低分子又や熱可塑性高分子をいう。例えば、尿素樹脂、メラミン樹脂、フェノール樹脂、エポキシ樹脂、不飽和ポリエステル樹脂、アクリル樹脂等で、これらの樹脂は、化学反応性官能基を分子中に有している。   Further, the thermosetting resin refers to a liquid or powdery low molecular weight or thermoplastic polymer having a property of causing a cross-linking reaction between molecules by heating or the like to change into an insoluble polymer having a three-dimensional network structure. . For example, urea resin, melamine resin, phenol resin, epoxy resin, unsaturated polyester resin, acrylic resin, and the like, these resins have chemically reactive functional groups in the molecule.

目封止パターンの印刷は、光又は熱硬化樹脂膜に光吸収性インク又は熱吸収性インク等を印刷しても良いし、支持体フィルムに光又は熱硬化樹脂を印刷しても良い。光又は熱硬化樹脂を印刷する支持体フィルムは、ポリエチレンフィルム、ポリプロピレンフィルム、ポリエステルフィルムが利用できる。これらのフィルムは予め表面処理をしてから用いることもできる。特に、インクジェット印刷には、例えば、ポリアクリル粉状物、不飽和ポリエステル粉状物等で処理するのが好ましい。表面処理には、コロナ放電処理を併用する
ことができる。
The plugging pattern may be printed by printing light-absorbing ink or heat-absorbing ink on the light or thermosetting resin film, or printing light or thermosetting resin on the support film. The support film on which the light or thermosetting resin is printed can be a polyethylene film, a polypropylene film, or a polyester film. These films can be used after surface treatment in advance. In particular, for inkjet printing, for example, it is preferable to treat with a polyacryl powder, an unsaturated polyester powder, or the like. Corona discharge treatment can be used in combination with the surface treatment.

次に、図2(a)〜(d)に基づいて、図1(a)〜(e)で得られた印刷済みのフィルムを端面に有するハニカム構造体に対する光又は熱照射による硬化、目封止材の固定の各工程について説明する。印刷済みフィルム32が貼り付けられたハニカム構造体31に対し、図2(b)のように、紫外線などの光源又はハロゲンランプなどの熱源37を用いて光又は熱を照射することにより、図2(c)のように、目的の箇所の膜33のみが硬化される。硬化されたセル部34の膜33はハニカム構造体31の端面で固定される。一方、硬化されなかったセル部35では、図2(c)(d)のように、加圧エア又はサンドブラストY等によって硬化していない箇所の膜36が除去される。なお、硬化された膜33は、次工程で、従来公知の方法により、目封止部材をセル内に充填してから除去しても良いし、ハニカム構造体の焼成により消失させても良い。このようにして、所望のパターンで端面が目封じされた目封止ハニカム構造体が製造される。   Next, based on FIGS. 2A to 2D, the honeycomb structure having the printed film obtained in FIGS. 1A to 1E on the end face is cured by light or heat irradiation, and sealed. Each step of fixing the stopper will be described. As shown in FIG. 2B, the honeycomb structure 31 with the printed film 32 attached thereto is irradiated with light or heat using a light source such as ultraviolet rays or a heat source 37 such as a halogen lamp. As in (c), only the film 33 at the target location is cured. The cured film 33 of the cell portion 34 is fixed on the end face of the honeycomb structure 31. On the other hand, in the cell portion 35 that has not been cured, as shown in FIGS. 2C and 2D, the film 36 at a location that has not been cured by the pressurized air or sandblast Y is removed. In the next step, the cured film 33 may be removed after filling the plugging members into the cells by a conventionally known method, or may be eliminated by firing the honeycomb structure. In this manner, a plugged honeycomb structure with an end face plugged in a desired pattern is manufactured.

次に、本発明における別の実施形態を、図3(a)〜(g)によって説明する。図3(a)に示すように、まず、ハニカム構造体41の全セル42内へスラリー状目封止材43を充填する。また、これとは別に、図3(b)に示すように、カメラ40にてハニカム構造体41の端面セルの画像を撮像する。次いで、図3(c)のように、全セルが目封じされたハニカム構造体41の端面に光又は熱硬化樹脂膜(フィルム)44を貼り付ける。その後は、図2(a)〜(d)と同様にして、図3(d)に示すように、フィルム44に目封じパターンを印刷した後、印刷済みフィルム44aが貼り付けられたハニカム構造体41に対し、図3(e)のように、光源又は熱源50を用いて光又は熱を照射することにより、図3(f)のように、目的の箇所の膜45のみが硬化される。硬化されたセル部46の膜45はハニカム構造体41の端面で固定される。一方、硬化されなかったセル部47では、図3(g)のように、加圧エア又はサンドブラストY等によって硬化していない箇所の膜48が目封止材49とともに除去される。なお、残った端面上の硬化した膜45は、通常手段により除去しても良いし、焼成によって消失させても良い。   Next, another embodiment of the present invention will be described with reference to FIGS. As shown in FIG. 3A, first, the slurry-like plugging material 43 is filled into all the cells 42 of the honeycomb structure 41. Separately from this, as shown in FIG. 3B, an image of the end face cell of the honeycomb structure 41 is taken by the camera 40. Next, as shown in FIG. 3C, a light or thermosetting resin film (film) 44 is attached to the end face of the honeycomb structure 41 in which all the cells are sealed. Thereafter, in the same manner as in FIGS. 2A to 2D, as shown in FIG. 3D, a honeycomb structure in which a printed pattern 44 a is pasted after a plugging pattern is printed on the film 44. By irradiating light or heat to 41 using a light source or heat source 50 as shown in FIG. 3E, only the film 45 at the target location is cured as shown in FIG. The cured film 45 of the cell portion 46 is fixed at the end face of the honeycomb structure 41. On the other hand, in the uncured cell portion 47, as shown in FIG. 3G, the film 48 at a portion that has not been cured by pressurized air, sandblast Y, or the like is removed together with the plugging material 49. Note that the cured film 45 on the remaining end face may be removed by ordinary means or may be eliminated by firing.

本発明におけるさらに別の実施形態を、図4(a)〜(d)によって説明する。図4(a)に示すように、予め目封止材52に光又は熱硬化樹脂を含有しておき、その目封止材52をハニカム構造体51の全セルに充填する。次いで、図4(b)に示すように、予め撮像されたハニカム構造体51の端面画像情報に基づいて、ハニカム構造体51の目封止材52が充填された端面を目封止パターン状(例えば、千鳥状)にレーザーXを照射することで、図4(c)のように、所定のセル53の目封止材52の表面部54を硬化させ、硬化した表面部54はハニカム構造体51の端面で固定される。一方、図4(c)(d)のように、硬化されなかったセル部55の目封止材56はサンドブラストY等によって除去される。   Still another embodiment of the present invention will be described with reference to FIGS. As shown in FIG. 4A, the plugging material 52 contains light or a thermosetting resin in advance, and the plugging material 52 is filled in all the cells of the honeycomb structure 51. Next, as shown in FIG. 4B, based on the end face image information of the honeycomb structure 51 imaged in advance, the end face filled with the plugging material 52 of the honeycomb structure 51 is plugged in a pattern ( For example, as shown in FIG. 4C, the surface portion 54 of the plugging material 52 of the predetermined cell 53 is cured by irradiating the laser X in a zigzag manner, and the cured surface portion 54 is a honeycomb structure. 51 is fixed at the end face. On the other hand, as shown in FIGS. 4C and 4D, the plugging material 56 of the uncured cell portion 55 is removed by sandblast Y or the like.

さらに、本発明における別の実施形態を、図5(a)〜(e)によって説明する。図5(a)に示すように、予めハニカム構造体61の端面の全セルに目封止材62を充填する。次いで、図5(b)のように、目封止材62が充填されたその端面上に光又は熱硬化樹脂膜63を形成する。次いで、図5(c)に示すように、予め撮像されたハニカム構造体61の端面画像情報に基づいて、ハニカム構造体61の光又は熱硬化樹脂膜63が形成された端面を目封止パターン状(例えば、千鳥状)にレーザーXを照射することで、図5(d)のように、所定のセル64の膜65を硬化させ、硬化した膜65はハニカム構造体61の端面で固定される。一方、図5(d)(e)のように、硬化されなかったセル部66の膜67は目封止材68とともに、サンドブラストY等によって除去される。   Furthermore, another embodiment of the present invention will be described with reference to FIGS. As shown in FIG. 5A, the plugging material 62 is filled in all the cells on the end face of the honeycomb structure 61 in advance. Next, as shown in FIG. 5B, a light or thermosetting resin film 63 is formed on the end face filled with the plugging material 62. Next, as shown in FIG. 5C, based on the end face image information of the honeycomb structure 61 imaged in advance, the end face on which the light or thermosetting resin film 63 of the honeycomb structure 61 is formed is plugged. As shown in FIG. 5D, the film 65 of the predetermined cell 64 is cured by irradiating the laser X in the shape (for example, zigzag), and the cured film 65 is fixed on the end face of the honeycomb structure 61. The On the other hand, as shown in FIGS. 5D and 5E, the uncured film 67 of the cell portion 66 is removed together with the plugging material 68 by sandblasting Y or the like.

なお、光又は熱効果膜63の形成は、端面へのフィルム貼付又は光又は熱効果樹脂の塗布のいずれであってもよい。また、硬化した膜65は、通常手段により除去してもよいし、焼成により消失させても良い。   Note that the formation of the light or heat effect film 63 may be either film sticking to the end face or application of light or heat effect resin. Further, the cured film 65 may be removed by ordinary means, or may be lost by firing.

なお、本実施形態の目封止ハニカム構造体の製造方法においては、上述した方法によって得られた、目封止ハニカム構造体に対して、その隔壁の内表面及び/又はその内部に触媒を担持させてもよい。例えば、目封止ハニカム構造体をDPFとして用いる場合は、隔壁に捕捉された堆積物(粒子状物質)の燃焼を促進させるような機能を有する触媒を担持させることが好ましい。このような触媒としては、例えば、貴金属系のPt、Pd、Rh等や、非金属系のペロブスカイト型触媒等を好適例として挙げることができる。触媒を担持させる方法については、従来のDPF等のフィルタに触媒を担持させる方法に準じて行うことができる。   In the method for manufacturing a plugged honeycomb structure of the present embodiment, a catalyst is supported on the inner surface of the partition wall and / or inside the plugged honeycomb structure obtained by the above-described method. You may let them. For example, when a plugged honeycomb structure is used as the DPF, it is preferable to support a catalyst having a function of promoting the combustion of deposits (particulate matter) trapped in the partition walls. Preferred examples of such a catalyst include noble metal-based Pt, Pd, Rh and the like, and non-metallic perovskite-type catalysts. The method for supporting the catalyst can be performed according to the conventional method for supporting the catalyst on a filter such as DPF.

以下、実施例に基づき、更に具体的に説明する。
(実施例1)
例えば、原料として、前述のタルク、カオリン、アルミナを主原料とするコージェライト化原料に、水とバインダー、界面活性剤等を調合し、分散混合、混練した成形原料を、土練機により円柱状に押出して、それを押出し成形機により押出し成形して流体の流路となる複数のセルを区画形成する隔壁、及び隔壁と一体的に形成された外壁を有する筒状のセル(ハニカム)成形体を得る。こうして得られた成形体を用いてハニカム構造体を製造する場合には、得られた成形体を乾燥後に所定長さに切断して乾燥体を得、この乾燥体両端面のセル群を交互に目封止した後に焼成して焼成体を得る。目封止材をセル内に充填する場合には、目封止材に振動を付与することでより充填が容易となり、また目封止深さが均一となるので好ましい。次に、この得られた焼成体の外周壁及び最外周から約1〜3セル分の隔壁を研削除去した後、セラミックコート材を外周に塗布して外周壁を形成することによってコージェライト質のハニカム構造体を得ることができる。
Hereinafter, based on an Example, it demonstrates further more concretely.
Example 1
For example, as a raw material, water, a binder, a surfactant, etc. are mixed with the above-mentioned cordierite-forming raw material mainly composed of talc, kaolin, and alumina, and the forming raw material is dispersed, mixed, and kneaded. A cylindrical cell (honeycomb) molded body having a partition wall which is formed by extruding into a plurality of cells and partitioning a plurality of cells serving as fluid flow paths by an extrusion molding machine, and an outer wall formed integrally with the partition wall Get. In the case of manufacturing a honeycomb structure using the formed body thus obtained, the obtained formed body is dried and cut into a predetermined length to obtain a dried body, and the cell groups on both ends of the dried body are alternately arranged. After the plugging, firing is performed to obtain a fired body. In the case of filling the plugging material in the cell, it is preferable to apply vibration to the plugging material so that the filling becomes easier and the plugging depth becomes uniform. Next, after grinding and removing about 1 to 3 cells of partition walls from the outer peripheral wall and outermost periphery of the obtained fired body, a ceramic coating material is applied to the outer periphery to form an outer peripheral wall. A honeycomb structure can be obtained.

具体的には、セルの断面形状が四角形、隔壁厚さが0.3mm、基準セル密度が300cpsi(46.5個/cm)、外周コート後のハニカム構造体の外形が円柱状(外径:191mm、長さ:203mm)、目封止深さ10mmのハニカム構造体を製造することができた。同様にして、セルの断面形状が四角形、隔壁厚さが0.3mm、基準セル密度が200cpsi(31個/cm)、外周コート後ハニカム構造体の外形が円柱状(外径:330mm、長さ:305mm)のハニカム構造体、外周コート後のハニカム構造体の外形が円柱状(外径:460mm、長さ:500mm)のものを得ることができた。 Specifically, the cross-sectional shape of the cell is a quadrangle, the partition wall thickness is 0.3 mm, the reference cell density is 300 cpsi (46.5 cells / cm 2 ), and the outer shape of the honeycomb structure after outer periphery coating is cylindrical (outer diameter) 191 mm, length: 203 mm), and a honeycomb structure having a plugging depth of 10 mm could be manufactured. Similarly, the cross-sectional shape of the cell is quadrangular, the partition wall thickness is 0.3 mm, the reference cell density is 200 cpsi (31 cells / cm 2 ), and the outer shape of the honeycomb structure after outer periphery coating is cylindrical (outer diameter: 330 mm, long The thickness of the honeycomb structure was 305 mm) and the outer shape of the honeycomb structure after the outer periphery coating was cylindrical (outer diameter: 460 mm, length: 500 mm).

これらのセル構造体の特性は、気孔率範囲40〜80%、平均細孔径範囲が5〜50μm、40〜800℃での軸方向の平均熱膨張係数範囲が約0.1〜2.0×10−6/℃であった。 These cell structures have a porosity range of 40 to 80%, an average pore size range of 5 to 50 μm, and an average average thermal expansion coefficient range in the axial direction at 40 to 800 ° C. of about 0.1 to 2.0 ×. 10 −6 / ° C.

また、同じ原料を用いて、セルの断面形状が八角形と四角形の組合わせ、隔壁厚さが0.41mm、基準セル密度が300cpsi(46.5個/cm)となる外径191mmから460mmの寸法を有するハニカム構造体を製造した。更には、外周加工されていない一体成形の外形が円柱状(外径:144mm、長さ:152mm)で、セルの断面形状が八角形と四角形の組合わせ、隔壁厚さが0.41mm、基準セル密度が300cpsi(46.5個/cm)、目封止深さ3mmのセル構造体及びセルの断面形状が四角形、隔壁厚さが0.43mm、基準セル密度が100cpsi(15.5個/cm)で同じ寸法、目封止深さのセル構造体を製造した。 In addition, using the same raw material, the cell cross-sectional shape is a combination of octagon and square, the partition wall thickness is 0.41 mm, and the reference cell density is 300 cpsi (46.5 cells / cm 2 ) from 191 mm to 460 mm in outer diameter. A honeycomb structure having the following dimensions was manufactured. Furthermore, the outer shape of the integral molding that is not processed on the outer periphery is a cylindrical shape (outer diameter: 144 mm, length: 152 mm), the cell cross-sectional shape is a combination of octagon and square, the partition wall thickness is 0.41 mm, the reference A cell structure having a cell density of 300 cpsi (46.5 cells / cm 2 ), a plugging depth of 3 mm, a cell cross-sectional shape of a square, a partition wall thickness of 0.43 mm, and a reference cell density of 100 cpsi (15.5 cells) / Cm 2 ) to produce a cell structure having the same dimensions and plugging depth.

目封止後に外周部を加工除去しセラミックコート塗布して外壁を形成する外周コートタイプのハニカム構造体においては、ハニカム構造体の最外周部に位置するパーシャルセルを必ずしも目封止する必要はないのであるが、外壁一体成形タイプのハニカム構造体においては、最外周に位置する目封止すべきパーシャルセルを目封止し、そうでないセルは目封止しないようにすることがフィルタ性能上好ましく、本方法ではパーシャルセルも忠実に撮像されて目封止パターンが形成されるので、外壁一体成形タイプのハニカム構造体においては、最外周に位置する目封止すべきパーシャルセルを目封止し、そうでないセルは目封止しないようにすることが可能となる。   In the outer peripheral coat type honeycomb structure in which the outer peripheral portion is processed and removed after plugging and the outer wall is formed by applying a ceramic coat, it is not always necessary to plug the partial cells located at the outermost peripheral portion of the honeycomb structure. However, in the honeycomb structure of the outer wall integral molding type, it is preferable in terms of filter performance to plug the partial cells to be plugged located on the outermost periphery and not plug the other cells. In this method, since the partial cells are also faithfully imaged and a plugging pattern is formed, in the honeycomb structure of the outer wall integral molding type, the partial cells to be plugged located on the outermost periphery are plugged. It becomes possible not to plug the cells that are not.

本発明に係る製造方法より得られた目封止ハニカム構造体は、化学、電力、鉄鋼、産業廃棄物処理をはじめとする様々な分野において、公害防止等の環境対策、高温ガスからの製品回収等の用途で用いられる集塵用のフィルタ、特に、ディーゼル機関から排出されるパティキュレートを捕集するディーゼルパティキュレートフィルタ(DPF)等の高温、腐食性ガス雰囲気下において使用される集塵用フィルタとして好適に用いられる。   The plugged honeycomb structure obtained by the manufacturing method according to the present invention is used in various fields including chemical, electric power, steel, industrial waste treatment, environmental measures such as pollution prevention, and product recovery from high-temperature gas. Filters for dust collection used in applications such as diesel filters, especially diesel particulate filters (DPF) that collect particulates discharged from diesel engines, etc., dust collection filters used in high-temperature, corrosive gas atmospheres Is preferably used.

(a)〜(e)は、本発明の一実施形態のうち、ハニカム構造体端面のフィルムへの印刷工程を示す工程図である。(A)-(e) is process drawing which shows the printing process to the film of a honeycomb structure end surface among one Embodiment of this invention. (a)〜(d)は、本発明の一実施形態のうち、図1(a)〜(e)に続く、ハニカム構造体に対する光又は熱照射による硬化、目封止材の固定の各工程を示す工程図である。(A)-(d) is each process of hardening by light or heat irradiation with respect to a honeycomb structure, fixing of a plugging material following FIG.1 (a)-(e) among one Embodiment of this invention. FIG. (a)〜(g)は、本発明の別の実施形態を示す工程図である。(A)-(g) is process drawing which shows another embodiment of this invention. (a)〜(d)は、本発明のさらに別の実施形態を示す工程図である。(A)-(d) is process drawing which shows another embodiment of this invention. (a)〜(e)は、本発明のさらに別の実施形態を示す工程図である。(A)-(e) is process drawing which shows another embodiment of this invention. (a)(b)は、目封止ハニカム構造体の従来の製造方法を示す工程図である。(A) (b) is process drawing which shows the conventional manufacturing method of a plugged honeycomb structure. 目封止ハニカム構造体の構成を示す断面図である。It is sectional drawing which shows the structure of a plugged honeycomb structure.

符号の説明Explanation of symbols

1:ハニカム成形体、2:フィルム、3:目封止セルに対応する部分、4:マスク、5:スラリー、11:ハニカム構造体、14:セル画像、15:合成画像、16:光又は熱硬化樹脂膜(フィルム)、17:印刷済みフィルム、18:カメラ、21:目封止ハニカム構造体、22:多孔質の隔壁、23:ハニカム構造体、24:セル、26:目封止部材、B:セルの入口側端面、C:セルの出口側端面、31:ハニカム構造体、32:印刷済みフィルム、33:硬化された膜、34:セル部、35:セル部、36:硬化していない箇所の膜、37:光源又は熱源、40:カメラ、41:ハニカム構造体、42:全セル、43:スラリー状目封止材、44:光又は熱硬化樹脂膜(フィルム)、44a:印刷済みフィルム、45:目的の箇所の膜、46:硬化されたセル部、47:硬化されなかったセル部、48:硬化していない箇所の膜、49:目封止材、50:光源又は熱源、61:ハニカム構造体、62:目封止材、63:光又は熱硬化樹脂膜、64:所定のセル、65:膜、66:硬化されなかったセル部、67:膜、68:目封止材、X:レーザー、Y:サンドブラスト。 1: honeycomb formed body, 2: film, 3: part corresponding to plugged cell, 4: mask, 5: slurry, 11: honeycomb structure, 14: cell image, 15: composite image, 16: light or heat Cured resin film (film), 17: printed film, 18: camera, 21: plugged honeycomb structure, 22: porous partition wall, 23: honeycomb structure, 24: cell, 26: plugging member, B: Cell end side end surface, C: Cell end side end surface, 31: Honeycomb structure, 32: Printed film, 33: Cured film, 34: Cell part, 35: Cell part, 36: Cured No film, 37: Light source or heat source, 40: Camera, 41: Honeycomb structure, 42: All cells, 43: Slurry plugging material, 44: Light or thermosetting resin film (film), 44a: Printing Finished film, 45: , 46: cured cell part, 47: uncured cell part, 48: uncured film, 49: plugging material, 50: light source or heat source, 61: honeycomb structure, 62: eye Sealing material, 63: light or thermosetting resin film, 64: predetermined cell, 65: film, 66: uncured cell part, 67: film, 68: plugging material, X: laser, Y: sandblast .

Claims (5)

多孔質の隔壁によって流体の流路となる複数のセルがハニカム状に区画形成された筒状ハニカム構造体の所定のセルの一方の開口端部に目封止部が形成された目封止ハニカム構造体の製造方法において、
予めハニカム構造体の端面を撮像し、次いで、予め決められた目封止パターンを撮像されたハニカム構造体端面の端面セル群に画像処理により合成し、得られた合成画像をハニカム構造体端面に形成された光又は熱硬化樹脂膜に印刷した後、ハニカム構造体端面に光又は熱を照射し、硬化した個所を残して除去することにより、前記光又は熱硬化樹脂膜に所定の目封止パターンを有する開口部を形成し、ハニカム構造体のセル内へ目封止材を充填して目封止部を形成することを特徴とする目封止ハニカム構造体の製造方法。
A plugged honeycomb in which a plugged portion is formed at one open end of a predetermined cell of a tubular honeycomb structure in which a plurality of cells serving as fluid flow paths are formed in a honeycomb shape by porous partition walls In the manufacturing method of the structure,
The end face of the honeycomb structure is imaged in advance, and then a predetermined plugging pattern is synthesized by image processing on the end face cell group of the end face of the honeycomb structure that has been imaged, and the resultant composite image is formed on the end face of the honeycomb structure. After printing on the formed light or thermosetting resin film, the end face of the honeycomb structure is irradiated with light or heat, and the cured part is removed leaving a predetermined plugging on the light or thermosetting resin film A method for manufacturing a plugged honeycomb structure, comprising forming an opening having a pattern and filling a plugging material into cells of the honeycomb structure to form a plugged portion.
予め光又は熱硬化樹脂フィルムに合成した目封止パターンを印刷しておき、そのフィルムをハニカム構造体端面に貼り付ける請求項1記載の目封止ハニカム構造体の製造方法。   The method for manufacturing a plugged honeycomb structure according to claim 1, wherein a plugged pattern synthesized in advance on a light or thermosetting resin film is printed, and the film is attached to an end face of the honeycomb structure. 多孔質の隔壁によって流体の流路となる複数のセルがハニカム状に区画形成された筒状ハニカム構造体の所定のセルの一方の開口端部に目封止部が形成された目封止ハニカム構造体の製造方法において、
予めハニカム構造体端面の全セルに目封止材を充填した後、その端面に光又は熱硬化樹脂膜を形成して、予めハニカム構造体の端面を撮像し、次いで、予め決められた目封止パターンを撮像されたハニカム構造体端面の端面セル群に画像処理により合成し、得られた合成画像をハニカム構造体端面に形成された光又は熱硬化樹脂膜に印刷した後、ハニカム構造体端面に光又は熱を照射して所定のセルの光又は熱硬化樹脂膜を硬化させ、硬化しなかった光又は熱硬化樹脂膜を目封止材とともに除去した後、硬化した光又は熱硬化樹脂膜を除去することにより目封止部を形成することを特徴とする目封止ハニカム構造体の製造方法。
A plugged honeycomb in which a plugged portion is formed at one open end of a predetermined cell of a cylindrical honeycomb structure in which a plurality of cells serving as fluid flow paths are formed in a honeycomb shape by porous partition walls In the manufacturing method of the structure,
After all the cells on the end face of the honeycomb structure are filled with a plugging material, a light or thermosetting resin film is formed on the end face, the end face of the honeycomb structure is imaged in advance, and then a predetermined plugging is formed. The stop pattern is combined with the end face cell group of the end face of the honeycomb structure imaged by image processing, and the resultant composite image is printed on the light or thermosetting resin film formed on the end face of the honeycomb structure, and then the end face of the honeycomb structure body Is irradiated with light or heat to cure the light or thermosetting resin film of a predetermined cell, and after the uncured light or thermosetting resin film is removed together with the plugging material, the cured light or thermosetting resin film A method for manufacturing a plugged honeycomb structure, wherein a plugged portion is formed by removing a plug.
多孔質の隔壁によって流体の流路となる複数のセルがハニカム状に区画形成された筒状ハニカム構造体の所定のセルの一方の開口端部に目封止部が形成された目封止ハニカム構造体の製造方法において、
予め目封止材に光又は熱硬化樹脂を含有しておき、その目封止材をハニカム構造体の全セルに充填し、予め撮像されたハニカム構造体の端面画像情報に基づいて、端面を目封止パターン状にレーザー照射することで、所定のセルの目封止材を硬化させ、硬化しなかった目封止材を除去することにより目封止部を形成することを特徴とする目封止ハニカム構造体の製造方法。
A plugged honeycomb in which a plugged portion is formed at one open end of a predetermined cell of a cylindrical honeycomb structure in which a plurality of cells serving as fluid flow paths are formed in a honeycomb shape by porous partition walls In the manufacturing method of the structure,
The plugging material contains light or thermosetting resin in advance, the plugging material is filled in all cells of the honeycomb structure, and the end face is determined based on the end face image information of the honeycomb structure captured in advance. An eye characterized by forming a plugging portion by irradiating a plugging pattern with a laser to cure the plugging material of a predetermined cell and removing the uncured plugging material. A method for manufacturing a sealed honeycomb structure.
多孔質の隔壁によって流体の流路となる複数のセルがハニカム状に区画形成された筒状ハニカム構造体の所定のセルの一方の開口端部に目封止部が形成された目封止ハニカム構造体の製造方法において、
予めハニカム構造体端面の全セルに目封止材を充填した後、その端面に光又は熱硬化樹脂膜を形成し、次いで、予め撮像されたハニカム構造体の端面画像情報に基づいて、端面を目封止パターン状にレーザー照射することで、所定のセルの光又は熱硬化樹脂膜を硬化させ、硬化しなかった光又は熱硬化樹脂膜を目封止材とともに除去した後、硬化した光又は熱硬化樹脂膜を除去することにより目封止部を形成することを特徴とする目封止ハニカム構造体の製造方法。
A plugged honeycomb in which a plugged portion is formed at one open end of a predetermined cell of a cylindrical honeycomb structure in which a plurality of cells serving as fluid flow paths are formed in a honeycomb shape by porous partition walls In the manufacturing method of the structure,
After filling all the cells on the end face of the honeycomb structure in advance with a plugging material, a light or thermosetting resin film is formed on the end face, and then the end face is determined based on the end face image information of the honeycomb structure taken in advance. By irradiating a laser in a plugging pattern, the light or thermosetting resin film of a predetermined cell is cured, and after the uncured light or thermosetting resin film is removed together with the plugging material, the cured light or A method for manufacturing a plugged honeycomb structure, wherein the plugged portion is formed by removing the thermosetting resin film.
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US7722791B2 (en) 2007-07-18 2010-05-25 Ngk Insulators, Ltd. Method for manufacturing honeycomb structure and manufacturing apparatus thereof
US7919033B2 (en) 2007-07-18 2011-04-05 Ngk Insulators, Ltd. Method of manufacturing honeycomb structure and manufacturing apparatus thereof
WO2017051806A1 (en) * 2015-09-24 2017-03-30 住友化学株式会社 Honeycomb filter, and method for producing honeycomb filter

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KR20100135699A (en) * 2007-12-17 2010-12-27 이머리 Ceramic honeycomb structure
WO2020009849A1 (en) 2018-07-03 2020-01-09 Corning Incorporated Selective masking and plugging of honeycomb bodies
JP7386626B2 (en) 2019-06-18 2023-11-27 株式会社キャタラー particulate filter

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US7722791B2 (en) 2007-07-18 2010-05-25 Ngk Insulators, Ltd. Method for manufacturing honeycomb structure and manufacturing apparatus thereof
US7919033B2 (en) 2007-07-18 2011-04-05 Ngk Insulators, Ltd. Method of manufacturing honeycomb structure and manufacturing apparatus thereof
US8192667B2 (en) 2007-07-18 2012-06-05 Ngk Insulators, Ltd. Apparatus for manufacturing a honeycomb structure
WO2017051806A1 (en) * 2015-09-24 2017-03-30 住友化学株式会社 Honeycomb filter, and method for producing honeycomb filter

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